Segmented Current Collector Assembly for Leak-Safe Liquid Cooling

Solution Overview

Problem

The machined-current-collector process for cylindrical battery packs requires significant labor and material resources, leading to high production costs and precision control difficulties, which are unfavorable for cost reduction and assembly efficiency.

Innovation Solution

A current collector assembly comprising a first and second current collector shell, capped with a blocker to form converging openings, allowing for individual processing and automated production, reducing processing difficulty and costs, while improving structural strength and precision.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If the machined-current-collector process is used to manufacture the current collector head, then the structural precision and integrity are improved, but the production cost increases and production efficiency decreases

Engineering Contradiction:

Improvecurrent collector head precisionVSAvoidproduction efficiency

Core Design Contradiction:

Manufacturing precisionVSProductivity

Solution Approach 1:

The current collector head is divided into multiple components: a shell body and an insert component. The shell body is formed by stamping process which enables automated production, while the insert component is separately manufactured and then assembled into the shell body through brazing. This segmentation allows each component to be optimized for its manufacturing process, achieving both precision and high productivity.

Inventive Principle:

Principle #1Segmentation

2Manufacturing precision

If the machined-current-collector process is used to manufacture the current collector head, then the structural precision and integrity are improved, but the production cost increases

Engineering Contradiction:

Improvecurrent collector head precisionVSAvoidproduction cost

Core Design Contradiction:

Manufacturing precisionVSEase of manufacture

Solution Approach 1:

The current collector head is divided into multiple components: a shell body and an insert component. The shell body is formed by stamping process which enables automated production, while the insert component is separately manufactured and then assembled into the shell body through brazing. This segmentation allows each component to be optimized for its manufacturing process, achieving both precision and high productivity.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The insert component serves as a precision template or copy that defines the internal cavity structure of the current collector head. By manufacturing the insert separately with high precision and then assembling it into the stamped shell body, the complex internal geometry is replicated accurately without requiring complex machining of the entire head, thereby reducing production cost while maintaining precision.

Inventive Principle:

Principle #26Copying

3Strength

If the current collector head is made by machined-current-collector process, then the structural strength is improved, but the difficulty of controlling precision during machining increases

Engineering Contradiction:

Improvecurrent collector head strengthVSAvoidprecision control difficulty

Core Design Contradiction:

StrengthVSManufacturing precision

Solution Approach 1:

The current collector head is divided into multiple components: a shell body and an insert component. The shell body is formed by stamping process which enables automated production, while the insert component is separately manufactured and then assembled into the shell body through brazing. This segmentation allows each component to be optimized for its manufacturing process, achieving both precision and high productivity.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The insert component is manufactured separately in advance with high precision before being assembled into the shell body. This preliminary action allows the precision-critical features to be created when the component is small and accessible, rather than attempting to machine precision features in the final assembled head, thereby reducing precision control difficulty while maintaining structural strength.

Inventive Principle:

Principle #10Preliminary action

Data Source

PatentEP4696973A1Current collector and liquid cooling assembly

Publication Date: 2026.02.18 EVE ENERGY CO LTD

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AI summary

A current collector includes: a first current collector shell (1); a second current collector shell (2), capped with the first current collector shell to form a current collector cavity having a converging opening (3); a current collector blocker (4), being inserted to an interior of the current collector cavity and dividing the current collector cavity into a first liquid guiding cavity (51) and a second liquid guiding cavity (52). Both the first liquid guiding cavity and the second liquid guiding cavity are communicated to the converging opening; the current collector blocker is arranged with a first bearing portion (41) attached to and supporting the first current collector shell and a second bearing portion (41) attached to and supporting the second current collector shell.